Week 3 Verification of Weld Joints

Verification of Weld Joints:

Aim:

To simulate three different types of welding using different weld materials as stainless steel,Aluminium alloy,Bronze and copper for the given welded joint.

Objective:

Simulate three different types of welding using three different weld materials

Weld Material used:

Case 1. Stainless Steel: In this case, the material of the plates must also be the same. Use Stainless steel for both weldments and plates. No need to add flux to the weldments.

Case 2. Aluminium Alloy:The material to be chosen for this case is Aluminium alloy(high strength, wrought). [Plate material to be used is stainless steel]

Case 3.Bronze: In order to simulate "Brazing", you should be using bronze as the weld material. Assign Stainless Steel to both plates and Copper to the "Ribs".

Run the simulation for a load of 15000N that is to be applied at the rectangular hole in the small plate(Same as in the video).

For each case, find out the Directional Deformation and equivalent strain experienced by the setup. Identify the weld joint that experiences the highest equivalent stress in each case and compare the results for all three cases

Procedure:

• Firstly open the ANSYS workbench software.
• Select static structural from analysis system.
• In the engineering data 'Stainless steel' is selected from general materials.

• And then import the geometry from the system files.
• The imported model is as follows.

• And in the geometry tab assign 'Stainless steel' to the weld joints,Plates and ribs.
• And in contacts change it to 'Rename based on definition'.

• And for then in connections assign frictional to the plates and ribs with a friction coefficient of 0.2.

• And we go for meshing in that select small plate and big plate for body sizing with a mesh value of 7mm.

• And then we proceed for meshing with a value of 6mm for the ribs.
• The mesh generated image is as follows.

• And in analysis settings switch on the large deflection.
• And then insert fixed support at the holes by selecting all the faces of the holes.

• And after that insert force at rectangular hole on the small plate by selecting the faces.

• And then in details of force as the force will be acting downward which is in Y- direction of co-ordinate system we apply a force load of 15000N.

• And we request for the setup solution like directional deformation,Equivalent strain and equivalent stress for the weld joints also.

Results:

CASE 1(Stainless steel):

Directional Deformation:

The directional deformation of the model is

Maximum- 0.34913 mm

Minimum- -0.032346 mm

• And by using 99(2x auto) will get a clear picture of force acting in y-direction.

GIF:

Equivalent Elastic strain:

The equivalent elastic strain of the compoenent is

Maximum-0.0018841 mm/mm

Minimum- 10124e-6 mm/mm

• Force acting in Y- direction

GIF:

Equivalent stress of whole body:

The equivalent stress of the model is

Maximum-342.99 mpa

Minimum-0.17059 mpa

• Force acting in Y- direction is

GIF:

Equivalent stress of weld joints:

The equivalent stress of weld joints are

Maximum-303.9 mpa

Minimum-1.9005 mpa

• Force acting in Y -direction

GIF:

CASE 2:

Aluminium alloy:

Aluminium alloy is used for ribs and weld joints.Stainless steel is used for the plates.

Directional Deformation:

The directional deformation of the model is

Maximum- 0.44701 mm

Minimum- -0.019658 mm

• Force acting in Y- direction is

GIF:

Equivalent Elastic Strain:

The equivalent elastic strain of the model is

Maximum-0.0037793 mm/mm

Minimum- 9.8688e-7 mm/mm

• Force acting in Y-direction is

GIF:

Equivalent stress of whole body:

The equivalent stress of the whole model is

Maximum-358.34 mpa

Minimum- 0.10502 mpa

• Force acting in y- direction

GIF:

Equivalent stress of weld joints:

The equivalent stress of weld joints are

Maximum-278.91 mpa

Minimum- 2.2621 mpa

• Force acting in Y-direction is

GIF:

CASE 3:

• Bronze is used for welding joints and stainless steel for plates and copper to ribs.

Directional deformation:

The directional deformation of the model is

Maximum-0.4068 mm

Minimum- -0.025185 mm

• Force acting in Y-direction is

Equivalent Elastic strain:

The equivalent elastic strain of the model is

Maximum-0.0033374 mm/mm

Minimum-6.7353e-7 mm/mm

• Force acting in Y-direction is

Equivalent stress of whole body:

The equivalent stress of the whole body is

Maximum-353.78 mpa

Minimum- 0.12998 mpa

• Force acting in Y-direction is

Equivalent stress of weld joints:

The equivalent stress of weld joints are

Maximum-266.85 mpa

Minimum-2.3545 mpa

• Force acting in Y-direction is

Tabular Data:

Directional Deformation(mm):

Cases Maximum Minimum

Case 1 0.34913 0.032346

Case 2 0.44701 0.019658

Case 3 0.4068 0.025815

Equivalent Elastic strain(mm/mm):

Cases Maximum Minimum

Case 1 0.0018841 1.124e-6

Case 2 0.0037793 9.8688e-7

Case 3 0.0033374 6.7353e-7

Equivalent stress of whole body(mpa):

Cases Maximum Minimum

Case 1 342.99 0.17059

Case 2 358.34 0.10502

Case 3 353.78 0.12998

Equivalent stress of Weld joints(mpa):

Cases Maximum Minimum

Case 1 303.9 1.9005

Case 2 278.91 2.2621

Case 3 266.85 2.3545

Conclusion:

From the above tabular data we can say that directional deformation is maximum for case 2 i.e aluminium and minimum in case 1 i.e stainless steel.And equivalent elastic strain is maximum in case 2 i.e aluminium and minimum in case 1 i.e stainless steel. The equivalent stress of whole body is maximum in aluminium andminimum in stainless steel.The equivalent stress of weld joints is maximum for case 1 i.e stainless steel and minimum in case 3 i.e bronze cast and copper alloy.